CIMLINE Magma 150 Owner's manual

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Melter Applicator
Owner/Operator Manual
2601 Niagara Lane · Plymouth, MN 55447 · [phone] · [phone] · Fax [phone]
Part # 161439 Revised 2/27/15
Magma 150, & 230

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Table of Contents
Shipping Papers and Information…………………….…….…3
Safety Notes……………………………………………….………4
Weights and Dimensions………………………………….……5
Controls and Their Functions………………………………..6-7
Start Up…………………………………………………………..8-9
Automatic Temperature Control Setting…………………….10
Loading Empty Tank…………………………………………….11
Cleanout Procedure……………………………………………..12
Cleanout Procedure (Optional Air Cleanout)………………..13
Maintenance…………………………………………………...14-15
Fluid and Components Specs…………………………………16
Heat Transfer Oil Specs………………………………………...17
Material Tank Capacity………………………………………….18
Trouble Shooting Guide………………………………………..19
Parts Section
Wiring Diagrams……………………………………………..21-27
Complete Wiring Diagram………………………………….21
Engine and Burner Wiring Harness………………..……..22
Switch Panel…………………………………………………..23
Temperature Control Wiring Diagram………………..…..24
Relay Panel ………………………………………………...…25
Main Supply Harness………………………………………..26
Primary Control…………………………………….………...27
Hydraulic Schematic……………………………..……………..28
Hydraulic Manifold Parts List………………………………….29
Electrical Components…………………………..……………..30
Isuzu Diesel Engine and Pump Parts List
(See supplement for compressor models)………………31
Plumbing System Parts List………………………………..32-33
Material Pump Parts List……………...…………………….34-35
Sealing Hose and Wand……...…...………….………………...36
Sealing Tips……………………………………………….……....37
Agitation System Parts List…………………………………….38
Oil Burner Parts List……………………………………………..39
Combustion Chamber Parts List and Tank Insulation.…....40
Fuel and Hydraulic Tank Components ..……………………..41
Miscellaneous Parts………………………………………….42-43
Spare Parts Kit……………………………………………………44
Compressor Option……………………………………………...45

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Shipping Papers and Information
A packet containing IMPORTANT INFORMATION has been enclosed with your Melter.
This packet contains:
1) Operation Instructions
2) Parts List
3) Warranty Information
4) Manufacturer's Documents
a) Engine
b) Material Pump
c) Burner (Diesel only)
IMPORTANT: This manual contains the basic information required to operate, main-
tain and repair the CIMLINE Melter you have purchased. The use of this manual in-
sures accurate adjustments, operation and proper lubrication of your equipment.
Please keep it handy.
Any parts orders or service problems relating to CIMLINE equipment should be di-
rected to the CIMLINE Parts Department at either [phone] or [phone].
When ordering parts, please have the following information available.
Serial Number: ____________________________
Model Number: ____________________________
Engine Model (H.P.): ____________________________
Engine Manufacturer: ____________________________
Pump Number: ____________________________
Replacement Part Number(s):

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PLEASE READ AND UNDERSTAND ENTIRE OPERATORS MANUAL BEFORE
PROCEEDING
WARNING: Protective clothing must be worn. Refer to ANSI Regulations:
1) Wear gloves with wristlets.
2) Wear long sleeve shirt with sleeves rolled down and cuffs buttoned.
3) Wear a face shield.
4) Load Melter from ground level.
5) Keep material door closed at all times except when adding material.
6) Never stand on any part of the machine.
7) Do not pull, twist, stretch or kink the material hose.
8) Do not operate without safety cover on hose.
9) Do not touch exhaust stacks or mufflers.
10) Wear heavy leather boots or shoes.
11) Wear long pants with no cuffs.
WARNING: Do not over fill the melting tank. For best results, add only as much material
as required for the job or a maximum of 75% of tank capacity. (Model 150 -
113 gallons, Model 230 - 168 gallons & Model 410 - 308 gallons).
WARNING: On a new Melter applicator or a unit that has been idle for some time, slowly
raise the oil temperature to 250º F and hold there for approximately 20 to 30
minutes. This will help get rid of any condensation that may be in the oil
chamber.
WARNING: Never leave machine unattended while it is running.
Safety Notes

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Model Number "A" in/cm "B" in/cm "C" in/cm Weight lbs/kg (empty)
150 84/214 156/396 95/242 4000/1814
230 81/206 171/435 90/229 4700/2132
Weights are without options
Model 230 shown
Weights and Dimensions

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NOTE: This general outline will only familiarize you with the machine. Read through the
entire manual before putting this machine into operation.
1) Pump Maintenance Valve: Allows the melted material to not leave the tank to allow
maintenance work on the pumping system.
2) Access Port: The sealing wand is placed in here when not in use. This allows operator
to continue circulating material through the hose to prevent material from cooling and
freezing up.
3) Loading Door (1 on Model 150): Place the material on safety door to load the melting
tank.
4) Oil Temperature Gauge: Monitors the heat transfer oil temperature.
5) Material Temperature Gauge (optional): This gauge shows the temperature of material
inside the melting tank. This gauge is for reference before pumping starts. Once pump-
ing begins, material controller will be an exact reading of material passing through the
system. (Not shown)
6) Micropanel ignition Switch: Use the key to turn the engine on and off.
7) Pressure Gauge: This gauge measures the pressure required to turn the agitator and
the material pump.
8) Sealing Hose Valve: This valve stops the material recirculating back into the material
tank causing it to go out of the wand.
9) Control Panel: The main control panel is used to control the direction of the material
pump and agitator, and you can also monitor the temperature of the material and heat
transfer oil.
10) Low Flow Override Switch: The Switch is engaged when in the up position. When
engaged this switch takes the signal from the wand switch and then tells the material
pump to engage. This function should only be used when material is coming out at a rate
higher than desired.
Caution: Failure to disengage this switch when not crack sealing could result in the
material becoming solidified in the plumbing.
Controls and Their Functions

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Controls and Their Functions
10
9

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1. SETUP:
A) Set Flow control to “9”
Make sure pump maintenance valve is
fully open Counter-Clockwise (Item “1”
from page 7).
B) Set all control switches to up
C) Set switch with
switch guard down.
2. START ENGINE:
A) Turn key on engine control to “1”
B) Heat glow plugs 3-5 seconds.
C) Turn key to “2”
D) Release when engine starts
Start up

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3. WAND
A) Unlock Boom
B) Place wand in port.
4. Ready for Work
When all 3 GREEN lights are on:
A) Set Flow to “0”
B) Pin Wand trigger
and set handle forward
C) Set Flow to
desired level
D) Start Sealing
Start up

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Automatic Temperature Control Setting
1) Press and hold set button (A) for 5 sec. Light (B) will turn on while in the setting mode.
2) Press "UP" or "DOWN" button until desired temp is shown.
3) Press set button (A) , light (B) will turn off and the readout will display actual
temperature.
4) Indicator light (B) will remain on anytime the burner is running.
The control system on your CIMLINE Magma melter has been factory set to run the most com-
mon types of materials. These materials have an application temperature of 380 deg F.
With some materials, it may be needed to change the controller to achieve the appropriate appli-
cation temperature. To achieve this, unscrew the clear plastic shield in the control box and alter
the material controller by following the directions below.

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Loading Empty Tank
All material must be clean. Keep all foreign matter out of melting tank.
1) Open the material door (1) and place slab or biscuit (2) on the open door against the
holder (3).
2) Push door to the closed position. DO NOT DROP MATERIAL INTO THE MELTER
WITH DOOR OPEN.
1
2
3

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Cleanout Procedure
1. SETUP:
A) Place wand in port.
B) Pin wand trigger and set handle for-
ward.
C) Place toggle switch with guard in
down position.
D) Set pump control switch to
reverse (R).
D) Set flow to “9”
Hose Clean-out:
Let pump run in reverse for 2 minutes.
Pump Clean-out:
Unpin wand trigger.
Continue running pump in reverse for 2 minutes.
Shut down:
Shut Engine off by turning key to “0”
Set all control switches up (leave toggle switch with guard in
down position).
Move Boom to travel position and
lock.
Store wand
Contact material supplier for information on
how to flush out non-reheatable materials.

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1. Place material pump in neutral (a)
2. Remove sealing tip and return wand to access port (b).
3. Pin wand trigger and set handle forward (c).
4. Close tank maintenance valve (d).
5. Connect air hose and open air cleanout valve (e).
6. Allow air to blow freely through sealing hose.
7. Move wand handle back and let air blow into tank (c).
8. Open Tank outlet valve momentarily, then close (d).
9. Shut air hose off at compressor, close air cleanout valve and dis-
connect hose (e).
10.Turn Key off and proceed with normal machine shut-down.
(a)
(b)
(c)
(d) (e)
Cleanout Procedure (Optional Air Cleanout)

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Maintenance
Engine: The operation and life of the engine depends on you and your operator. Do not start
engine until the engine precheck is complete. The engine precheck consists of checking the oil,
the fuel level, the hydraulic oil level and the air filter. The 150/230 Melter Applicator has the op-
tion of (2) different engines. The Isuzu 22.8 H.P. and 40.3 diesel units. For more detailed infor-
mation please refer to the Engine Operator Maintenance Manual and Warranty provided with
your Melter applicator.
NOTE: When breaking in a new Melter, we recommend running the engine for one
hour with no load prior to actual use on the job.
Air cleaner: Due to the dusty conditions that can be created by road work, it is essential to
check the engine air cleaner element daily. Remove element and shake out the accumulated
dust and dirt. Wipe out dirt from inside cover and from housing. Check engine manual for
washing instructions. We recommend stocking replacement filters.
Fuel: Use of high quality detergent oil of API (American Petroleum Institute) service class CC
or CD grade. Select the viscosity based on the air temperature at the time of operation. Check
your engine manual for other recommendations.
Burner: There are several items that need to be inspected periodically on the burners. These
items include the burner nozzle, electrode and head position, chamber lining (see below) and
the electric eye. Please refer to the burner manual on how to perform each of these operations
in this manual..
After each 200 hours of operation, the chamber lining should be inspected. Remove (8) burner
mount securing bolts (A) and pull out burner and mount. Inspect lining (B) for excessive crack-
ing. Also check the condition of retainer (C). Lining cracks are acceptable as long as they are
not large enough to allow flame to contact the combustion chamber walls.
(A)
(B)
(C)

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Maintenance
Maintenance Operation Daily 25 Hrs 100 Hrs 200 Hrs 1000 Hrs Yearly
Check fuel level (add if low) X
Check engine and heat transfer oil (add if low) X
Check hydraulic oil (add if low) X
Check engine air cleaner X
Inspect pre-cleaner X
Cleanout material system X
Inspect sealing hose and cover X
Inspect sealing hose connection X
Drain condensation from air compressor option X
Blow oil cooler on the air compressor option X
Inspect and clean cooling system (Diesel units only X
Inspect material pump packing (adjust if leaking is excessive) X
Check oil level on air compressor option X
Service air cleaner element X
Inspect spark plugs and breaker pts. (Propane units only) X
Inspect burner motor brushes (replace if worn out X
Inspect burner nozzle, electrode & head pos. (adjust if nec.) X
Change engine oil and oil filter X
Grease agitator bearing block (load adapter) X
Inspect fuel filter (replace if dirty) X
Inspect Diesel burner electric eye (clean if dirty) X
Grease wheel bearings X
Inspect chamber lining (replace if excessive cracking) X
Change oil on compressor option X
Change air inlet filter on compressor option X
Inspect starting motor X
Replace hydraulic oil X
Replace hydraulic return filter X
Replace hydraulic suction strainer X
Replace burner nozzle X
Change heat transfer oil X
Change Diesel fuel filter X
Flush radiator and replace fluid (Diesel units only) X
Replace separator on air compressor X

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Fluid and Components Specifications
WARNING: Only the oil specified or equal may be used in this system. (Always check
your local and state regulations before disposal).
NOTE: A dipstick (A) is provided for checking oil level when cold.
*This is a petroleum based product, it can be mixed with other petroleum based hydraulic oils
such as Dextron III or common straight weight oils. We recommend that you do not mix oil
brands. Mixing any oils (engine oil, transmission fluid, etc.) adversely affects each manufacturers
formula.
COLD OIL LEVEL
Model
150
Model
230
Hydraulic Reserve Capacity 30 Gallons
Hydraulic Oil Type Conoco MV32 or equiv
Diesel Fuel Capacity 30 Gallons
Diesel Fuel Type ASTM D975 No.2
Heat Transfer Oil Capacity 21 Gal. 26 Gal. .
Heat Transfer Oil Type See Specs. On next page.
Agitation Drive Relief Setting 1100 800
Material Pump Drive Relief Set-
ting 800
Material Pump Displacement .11 Gal/Rev
Material Pump Maximum Out-
put Pressure 125 PSI

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Heat Transfer Oil Specifications
ISO Grade 68 Heat transfer Oil Specification
There are many different types of Heat Transfer Oils on the international marketplace. It is criti-
cal that you use the proper oil to prevent poor performance, oil flashing, or auto-ignition. To
conform to most government bids and to supply a readily available product, CIMLINE typically
uses brands manufactured by Conoco or Phillips 66 that meet the ISO Grade 68 Heat Transfer
Oil specifications listed. To insure maximum safety and performance, we recommend you pur-
chase your oil through CIMLINE.
ISO VG# 68
Pour Point - F 10º F (12º C)
Flash Point - F 485º F (252º C)
Lbs/Gallon 7.27
Viscosity CsT @ 40C 62
IMPORTANT NOTICE!!
The ISO Grade is just a viscosity index (ability to flow/thickness). An ISO Grade 68 oil can be
an engine oil, hydraulic oil, etc. The manufacturer uses different additives to make the oil con-
form to different applications. YOU MUST CLARIFY with the supplier that the oil is to be used
in a heat transfer system to avoid any potential problems. Oil is also available from CIMLINE in
5 and 30 Gallon containers for ship-out.
NOTE: CIMLINE Melter/Applicators include and expansion tank that cools the oil that is ex-
posed to the outside air. When the oil heats up and expands, it flows into the expansion tank.
The tank is cooler since it is not oil jacketed and is surrounded by outside airflow. The only ex-
posure the hot oil has to the atmosphere is through a 3/4" vent/overflow pipe. This is done so
the oil in the tank can run higher than the flash point. Only the lower temperature oil fumes are
exposed to the atmosphere.
FLASH POINT - Test in which an open container of oil is heated until an open flame will flash
when passed over the fumes.
FIRE POINT - Same test as the flash point except the oil is heated until the gasses will start a
fire.
AUTO IGNITION POINT - The point at which fumes will burst into flame when exposed to air.

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Material Tank Capacity
MATERIAL CAPACITY
(Tank cutaway)
Gallons of material is found by first dividing the tank volume by 231 (# of cubic inches
per gallon of liquid), and then multiplying that number by the number of inches of mate-
rial in the tank. For example, 1052 divided by 231 = 4.55. 4.55 x 2" of material = 9.11.
* Volume of tank in cubic inches for each inch of material.
MATERIAL VAT
MODEL 230
9.37 GALLONS
PER INCH
INSULATION
AIR
OIL
MODEL 150
6.8 GALLONS PER INCH
Material
Depth
Model 150
1570 Cubic
Inches
Model 230
2165 Cubic
Inches
2" 13.6 18.74
4" 27.18 37.48
6" 40.78 56.22
8" 54.37 76.96
10" 67.96 93.7
12" 81.56 112.44
14" 95.15 131.18
16" 108.74 149.92
18" 122.34 168.66
20" 135.93 187.4
22" 149.52 204.14
24" 224.88
26"
28"

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MODEL 230
9.37 GALLONS
PER INCH
Trouble Shooting Guide
Problem Cause Solution
Burner will not ignite
Fuse burned out. Check fuse
Burner relay inoperative. Check for 12VDC at relay.
Primary control fuse. Check fuse
Thermocouple(s) inoperative Replace thermocouple(s)
Agitator will not rotate
Fuse burned out. Check fuse
Sealant material not hot enough. Allow material to heat longer
Too many biscuits added at one
time. Continue heat up and reverse agitation
to break biscuits free.
Low hydraulic oil level. Check oil Level
Worn agitator motor. Replace Motor
Material pump will not ro-
tate
Fuse burned out. Check fuse
Sealant material not hot enough. Allow material to heat longer
Too much material left in lines Heat plumbing and valve to melt material
Low hydraulic level Check oil level
Foreign object lodged in line Remove foreign object
Pump damaged Repair or replace pump
Material pump rotates but
does not pump material
Pump worn or damaged Repair or replace pump
Pump rotating in wrong direction Reverse pump switch
Pump inlet line plugged
Check matl tank grid and lines for ob-
struction
Too much material left in lines
from previous use. Heat plumbing and valve to melt material
Material heat up time slow
Burner orifice clogged Remove orifice and clean
Heat transfer oil is worn out Check oil level. Replace if necessary
Too much old material on tank
walls Clean material tank
Material recirculates but
will not flow through seal-
ing wand.
Sealing hose valve not completely
closing or worn out Realign valve or replace
Actuator not turning valve
Check Fuse
Check trigger switch
Broken or disconnected wire in the elec-
tric hose or at the switch

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Parts Section